Resin-composite aluminum profiles, heat insulating aluminum profiles, and method and apparatus for production thereof

ABSTRACT

A method is disclosed for producing a resin-composite profile. The method comprises providing an aluminum profile having a coating film that is capable of forming a functional group which reacts with isocyanate. A discharge treatment is performed on the film wherein the treated surface is capable of reacting with isocyanate. A urethane resin substantially formed of isocyanates and polyol is joined to the discharge treated surface.

This is a division of application Ser. No. 09/090,948, filed Jun. 5,1998, now U.S. Pat. No. 6,143,372, incorporated herein by reference.

BACKGROUND OF THE INVENTION

1. Field of the Invention

This invention relates to a technique for the union between an aluminumprofile and a resin material, and more particularly to resin-compositealuminum profiles having a resin material joined to an aluminum profile,especially heat insulating aluminum profiles having the joined parts ofopposed lateral sheet members of an aluminum profile formed with a resinmaterial, a method for the production of the profiles, and an apparatus,particularly a discharge treatment apparatus to be used for theproduction of the profiles.

The term “aluminum profile[s]” is used herein to express the shapes orsections of aluminum or an aluminum alloy shaped into a continuous form(hereinafter referred to simply as “profile[s]”) and the term“resin-composite aluminum profile[s]” is used to express the conceptembracing the heat insulating aluminum shapes or sections (hereinafterreferred to simply as “heat insulating profile[s]”).

2. Description of the Prior Art

The composite profiles having a resin material joined to the surface orrecess of a profile have been used in various technical fields becausethey are light and excellent in durability, strength, or the like.Particularly, in the technical field of construction, sashes which areprovided on either of the exterior and the interior side of buildingwith a double paper sliding door disposing part have been disseminatingwith a view to affording insulation from heat, abating noise, andpreventing dew condensation. The heat insulating profiles are used inthe frames of such sashes.

The heat insulating profile is provided between the opposed lateralsheet members thereof with a joined part formed of synthetic resin and,in this structure, allowed to have the opposed lateral sheet membersintegrally joined by the adhesive force of the resin material and, owingto the intervention of the resin material between the opposed sheetmembers, enabled to manifest the functions of affording insulation fromheat, abating noise, and preventing dew condensation. As the resinmaterial mentioned above, generally a foamable hard polyurethane resinis used as taught in published Japanese Patent Application, KOKAI (EarlyPublication) No. 54-19, 537, for example.

Generally in the production of the heat insulating profile, a urethaneresin material is injected to capacity into a recess provided betweenthe coated, opposed lateral sheet members of a profile and wished to bepacked with a resin and thereafter the portion of the profile whichforms the recess is cut so that the opposed lateral sheet members arejoined to each other solely with the urethane resin.

Since the adhesive force produced by the urethane resin is notsufficient, however, the resin and the profile are liable to peel offeach other. Once the separation of this sort occurs, the profile has theproblem of emitting a squeak when deformed under an external force andbetraying deficiency in strength as well. Further, the heat insulatingprofile entails the problems of durability such as causing shrinkage ofthe urethane resin after a protracted use, tending to induce thephenomenon of giving rise to a step in the butt end (discernible by atest of repeating cycles of cooling and heating), and possibly insertinga crack in the face of union and inducing leakage of rain water throughthe crack. For the purpose of compensating the urethane resin for theshortage of adhesive force, such measures as applying a primer layer tothe inner surface of the recess in the profile wished to be filled withresin or mechanically forming a multiplicity of claw parts on the innersurface have been heretofore proposed. These measures, however, entailhighly expensive treatments, require introduction of expensive devices,and suffer poor productivity. These treatments are not easily performeduniformly on the inner surface of the recess, particularly so when ahole-forming part for a screw is protruded into the recess.

SUMMARY OF THE INVENTION

It is, therefore, an object of the present invention to develop atechnique for improving the adhesive force to be generated between aprofile and a resin by a relatively simple and inexpensive method and,therefore, allow manufacture of the composite profiles or heatinsulating profiles having a profile and a resin joined fast to eachother at a low cost with high efficiency.

Particularly, the present invention has for an object thereof theprovision of the composite profiles, especially the heat insulatingprofiles, which allow easy treatment of the recess wished to be filledwith resin even when a hole-forming part for screw is protruded into therecess, produce high adhesive strength between a profile and a resin,prevent the profile from emitting a squeak even on exposure to anexternal force, exhibit high strength, offer strong resistance to theshrinkage of resin, entail virtually no phenomenon of giving rise to astep in the butt end, and excel in durability enough to withstand aprotracted use and a highly efficient method for the manufacturethereof.

A further object of the present invention is to develop an apparatus,particularly an electrode for a discharge treatment apparatus, which canbe advantageously used for the method described above.

To accomplish the objects described above, the present invention in thebasic aspect thereof provides a method for the production of aresin-composite profile characterized by performing a dischargetreatment on the surface of the portion of a coated profile destined forunion with resin and joining a resin material to the discharge treatedportion. When the profile has a recess wished to be packed with resin,the discharge treatment is performed on the inner surface of the recessand the discharge treated recess is filled with the resin material.

The adoption of this method equals the provision of a resin-compositeprofile which has a resin material joined fast integrally to thedischarge treated portion of the coated surface of the profile.

The profile to be effectively used for the present invention may be aprofile having a coating film formed by a coating treatment on thesurface of a profile of aluminum or an aluminum alloy, generally anextruded profile, or a profile having formed thereon a composite filmcomprising an anodic oxide film, colored oxide film, or chemicalconversion film and a coating film superposed thereon. Thus, a profilefurnished on the surface thereof with a coating film is invariablyusable for the present invention. The coating treatment involved hereinmay be performed by any of the heretofore known methods such as, forexample, electrodeposition coating, immersion coating, and electrostaticcoating.

In accordance with another aspect of the present invention, there isprovided a method for the production of a heat insulating profilecharacterized by performing a discharge treatment on the inner surfaceof a recess disposed between opposed lateral sheet members of a coatedprofile and intended to be filled with resin, filling a resin materialin the discharge treated recess, and then cutting the portion of theprofile forming the recess, thereby obtaining a heat insulating profilehaving the opposed lateral sheet members integrally joined to each otherwith the resin material filled as described above. When the profilementioned above has at least two recesses disposed between the opposedlateral sheet members and destined to be filled with resin, thedischarge treatment and the packing of resin material are performed onthe interior of one of the recesses and then the portion of the profileforming the other recess is cut when the portion of the profile formingthe recess mentioned above is subsequently cut, a resin sheet issuperposed on the cut portion of the other recess to occlude this cutportion, and subsequently the discharge treatment and the packing ofresin material are performed on the interior of the other recess.

The adoption of this method results in the provision of a heatinsulating profile which has the joined part of the opposed lateralsheet members of a coated profile, the joined part (joining member)being formed of a resin material joined fast integrally to the dischargetreated portions of the opposed surfaces of the opposed lateral sheetmembers.

The present invention further provides an apparatus for the productionof the composite profile or heat insulating profile mentioned above,characterized by being furnished at least with means for conveying acoated profile, discharge means disposed so as to be freely approximatedto the profile on the conveying means for the purpose of performing adischarge treatment on the profile in motion on the conveying means, andresin filling means disposed on the downstream side of the dischargemeans and adapted to be freely approximated to the profile on theconveying means. The apparatus for the production of a heat insulatingprofile is furnished on the downstream side of the resin filling meanswith a device for cutting the resin-filled recess portion of the profilesimilarly in the standard apparatus for production and, when the profilehas at least two recesses, furnished further with a device for sealingthe cut recess portion with a resin sheet.

The present invention further provides an electrode for the dischargetreatment of a profile, which can be used advantageously for thedischarge treatment mentioned above. Preferably the electrode comprisesa base part shaped like a rod or a plate and connected to a high-voltagepower source and a projecting part adapted to protrude laterally fromthe lower terminal portion of the base part and confront the innersurface of a recess to be treated when the projecting part is, insertedinto the recess of a profile. In a preferred embodiment, the projectingpart comprises a plurality of-linear materials having the upper endsthereof bundled and fixed to the lower terminal portion of the basepart.

The use of the apparatus of the present invention mentioned above,particularly the use of the aforementioned electrode for the dischargetreatment, allows the discharge treatment to be performed effectivelyand continuously on the part of the surface of a coating film of theprofile which is wished to be treated and results in improving theproductivity of the composite profile and the heat insulating profile.

BRIEF DESCRIPTION OF THE DRAWINGS

Other objects, features, and advantages of the invention will becomeapparent from the following description taken together with thedrawings, in which:

FIGS. 1A through 1F are schematic explanatory diagrams illustrating aprocess for producing a heat insulating profile according to the methodof the present invention;

FIG. 2 is a fragmentary perspective view illustrating one example of analuminum sash formed by assembling heat insulating profiles of variousstructures;

FIG. 3 is a fragmentary cross section of a heat insulating profilehaving a hole-forming part for a screw;

FIG. 4 is a cross-sectional view illustrating the state in which anelectrode for discharge treatment is inserted into a pouring pocket inthe lower frame;

FIGS. 5 through 9 are perspective views illustrating various kinds ofelectrode; FIG. 5 depicting an electrode shaped like a round rod, FIG. 6an electrode shaped like a plate, FIG. 7 an electrode shaped like adisc; and FIG. 8 and FIG. 9 electrodes of other shapes;

FIG. 10 is a fragmentary perspective view illustrating one example of adevice for corona discharge treatment;

FIG. 11 is a perspective view illustrating one example of a device foradjusting the position of an electrode;

FIG. 12 is a fragmentary perspective view illustrating the state inwhich an electrode shaped like a plate is inserted into a pouring pocketof a profile;

FIG. 13 is a fragmentary perspective view illustrating the state inwhich an electrode shaped like a disc is inserted into a pouring pocketof a profile;

FIG. 14 is a partially sectioned perspective view illustrating the statein which resin is being poured into a pouring pocket of a profile;

FIGS. 15 through 17 are graphs showing changes of the amount offunctional groups in the surface of a coating film before and aftervarious coated profiles have undergone a discharge treatment; and

FIG. 18 is a graph showing the change of the ratio of shrinkage ofurethane resin found by a test of repeated cycles of cooling and heatingperformed on various kinds of heat insulating profiles.

DETAILED DESCRIPTION OF THE INVENTION

The production of a composite profile or heat insulating profileaccording to the present invention is basically characterized byincreasing the adhesive strength between resin and a profile byperforming a discharge treatment in advance on the coated surface of theresin-joining portion of a profile or the coated inner surface of arecess formed in the profile and destined to be packed with resin. Whenthe discharge treatment of this sort is performed, the chemical bondsbetween the resin molecules forming a coating film on the surface of theprofile are severed and free hydrophilic functional groups such as, forexample, —OH, —COOH, ═NH, —NH₂, —SH, —SOH, or —NHCO— are formed,depending on the kind of coating material used, by the discharge energyor liberated electrons, with the result that the resin on the surface ofthe coating film will acquire improved wettability. It is alsoconceivable that the ozone generated by electric discharge will activatethe surface of the coating film and improve the affinity of the surfacefor the resin. These actions markedly exalt the adhesive strengthbetween the resin and the profile and, even in the heat insulatingprofile of a structure such that the opposed lateral sheet membersthereof are joined to each other solely with a resin material interposedtherebetween, allow integral union with markedly high adhesive strength.The heat insulating profile itself, therefore, acquires enhancedstrength, avoids emitting a squeak on exposure to an external force,offers high durability to resist the shrinkage of resin during aprotracted use, and entails virtually no possibility of forming a stepin the butt end. Particularly, when the resin material to be used forfilling is such a resin as a urethane resin which is formed ofisocyanate and polyol and therefore possessed of a functional groupcapable of reacting with the free functional group to be formed on thesurface of a coating film in consequence of the discharge treatmentmentioned above, the reaction between these functional groups exalts theadhesive strength to a very high extent.

The coating film on the surface of the profile is only required to becapable of forming such a hydrophilic functional group as mentionedabove in consequence of the discharge treatment. As concrete examples ofthe coating film answering this description, the coating films whichresult from applying acrylic resin coating material, acryl-melamineresin coating material, polyester coating material, polyurethane coatingmaterial, melamine resin coating material, acryl-silicone resin coatingmaterial (having two or more fluorine atoms bound to a silane group) bysuch a coating method as electrodeposition coating, immersion coating,or electrostatic coating may be cited.

In contrast, as the resin material to be joined to or filled in aprofile, various kinds of heat insulating resin such as, for example,urethane resins or epoxy resins of the cold-setting type, or acrylicresins of the photo-setting type can be used. Among other heatinsulating resins mentioned above, the urethane resins which possesssuitable flexibility at normal room temperatures or in a range of lowtemperatures and retain strength and suitable rigidity in a range ofhigh temperatures prove to be particularly advantageous.

As concrete examples of the method for performing the dischargetreatment, (1) a method which comprises performing a corona discharge ona given coating film at normal room temperature under normal pressurethereby effecting a surface treatment of the coating film (coronadischarge treatment), (2) a method which comprises performing a glowdischarge on a given coating film in a vacuum thereby treating thesurface of the coating film (ionic treatment), and (3) a method whichcomprises sealing a given coating film in a vacuum containing a tracequantity of a monomer and an inert gas and performing a glow dischargeon the coating film to effect a surface modification of the coating film(plasma treatment) may be cited. These methods are invariably capable ofmodifying the surface of the coating film of a profile by virtue ofelectric energy. Among other methods mentioned above, the method ofcorona discharge treatment which can be carried out rather simply atnormal room temperature under normal pressure at a low cost proves to beparticularly advantageous. The treating devices available for the coronadischarge treatment are broadly known in three types, i.e. a spark gapsystem, a vacuum tube system, and a solid state system. For thedischarge treatment contemplated by the present invention, any of thesesystems can be effectively adopted.

The conditions for the discharge treatment are preferred to be set suchthat the surface of the coating film of a discharge treated profileregisters a surface tension of not less than 45 dyn/cm or causes 5 μl ofwater drops poured thereon to spread over an area of not less than 3.5cm, preferably not less than 3.7 cm in diameter. These conditions can beadjusted, for example, by suitably setting the speed of conveyance ofthe profile or the magnitude of discharge voltage or other dischargeconditions.

Now, the present invention will be described more specifically belowwith reference to the annexed drawings.

FIGS. 1A through 1F illustrate one example of the process to beperformed when the method of the present invention is applied to theproduction of a heat insulating profile.

First, as illustrated in FIG. 1A, an electrode 20 for dischargetreatment is inserted into one (3) of two resin filling recesses 3 and 4(hereinafter referred to as “pouring pockets”) disposed between opposedlateral sheet members 2 a and 2 b of a coated profile 1 in such a manneras to interconnect the sheet members 2 a and 2 b and it is operatedtherein to perform a discharge treatment on the inner surface of thepouring pocket 3. Then, as illustrated in FIG. 1B, a resin 5 is pouredinto the discharge treated pouring pocket 3 and allowed to set therein.And the profile 1 is turned upside down. By the use of a suitablecutting tool (not shown), part of a bottom portion 4 a is cut from theother pouring pocket 4 side as illustrated in FIG. 1C and, at the sametime, part of the bottom portion 3 a of the other pouring pocket 3 islikewise cut. (Incidentally, when the profile 1 possesses only onepouring pocket 3, the cutting tool may be inserted through an opening onthe bottom portion 3 a side and manipulated to cut part of the bottomportion 3 a.)

Then, as illustrated in FIG. 1D, a resin sheet 6 is applied fast to thebottom portion 4 a of the other pouring pocket 4 so as to cover the cutopening part 4 b. Various kinds of synthetic resin sheet may be used asthe resin sheet 6. This resin sheet 6 is preferred to be a sheet ofpolyester which possesses fair rigidity and forms a free hydrophilicfunctional group like —COOH in consequence of discharge treatment. Thethickness of this resin sheet 6 which is proper for the presentinvention generally falls in the approximate range of 150-180 μm,depending on the kind of the resin sheet to be used. Thereafter, asillustrated in FIG. 1E, the electrode 20 for discharge treatment isinserted into the other pouring pocket 4 and operated to perform adischarge treatment on the surfaces of the pouring pocket 4 and resinsheet 6. Subsequently, by pouring the resin 5 into the pouring pocket 4which has undergone the discharge treatment as described above andallowing the resin to set therein, a heat insulating profile 10 havingthe opposed lateral sheet members 2 a, 2 b joined fast integrally toeach other with a pair of joined parts formed of the resin 5.

Alternatively, the process of discharge treatment may be performed firston the upper and lower pouring pockets 3 and 4 (by performing thedischarge treatment on the pouring pocket 3 as illustrated in FIG. 1A,then turning the profile 1 upside down, and subsequently performing thedischarge treatment on the pouring pocket 4, for example) and thereafterthe steps of FIGS. 1B, 1C, 1D, and 1F may be carried out.

In the case of a profile having three pouring pockets, it ismanufactured in a structure such that an opening part is formed inadvance in the bottom portion of one of the opposite pouring pockets. Onthis pouring pocket, therefore, the discharge treatment and the fillingof resin can be performed in accordance with the process of FIGS. 1Dthrough 1F mentioned above.

FIG. 2 illustrates part of one example of an aluminum sash formed byassembling heat insulating profiles of various structures produced bythe method described above. In the diagram, the reference numeral 11represents an outer meeting stile, 12 a lower rail, 13 a lower frame,and 14 a vertical frame, which are invariably heat insulating structuresusing the resin 5. The reference numerals 15 a and 15 b each represent adouble-wall glass. Owing to the structure of this sort, the producedaluminum sash excels in the ability to offer insulation from heat, theability to prevent dew condensation, and the durability. Further, sincethe component heat insulating profiles excel in adhesive strength withthe resin, the aluminum sash will not emit a squeak even when it isaccidentally exposed to an external force.

FIG. 3 is a fragmentary cross section illustrating one example of a heatinsulating profile 10 a having a hole-forming part 8 for screw protrudedinto a pouring pocket 7 similarly in the lower rail 12 illustrated inFIG. 2. According to the method of the present invention, the dischargetreatment and the filling of resin can be easily performed even on thepouring pocket 7 which is furnished with the hole-forming part 8 forscrew.

Incidentally, a cut part 7 b of a bottom portion 7 a of the pouringpocket 7 in this structure is generally held to be one of the basalparts of the hole-forming part 8 for screw.

FIG. 4 illustrates one example of the insertion of a discharge treatmentelectrode 20 a into a pouring pocket 9 of the lower frame 13 illustratedin FIG. 2. The discharge treatment electrode 20 a is depicted herein asbeing lined with a silicone rubber 21.

The electrode to be used in the discharge treatment can be made invarious shapes as illustrated in FIG. 5 through FIG. 9.

FIG. 5 illustrates an electrode 20 b shaped like a round rod and FIG. 6illustrates an electrode 20 c shaped like a plate. These electrodes eachhave a high-voltage lead wire 23 set in place with a screw in the upperpart thereof. The reference numeral 22 represents a porcelain insulator.FIG. 7 illustrates an electrode 20 d shaped like a disc. The electrode20 d is rotatably attached to a bracket 25 through the medium of a pin24 having the high-voltage lead wire 23 connected thereto.

An electrode 20 e illustrated in FIG. 8 has a structure such that aprojecting part 27 whose cross section laterally diverges in the shapeof the letter V is fixed to the lower terminal portion of a rodlike basepart 26 having the high-voltage lead wire 23 connected thereto. Theprovision of this projecting part 27 brings about such advantages asimparting elasticity to the relevant portion, facilitating the insertionof the electrode into the pouring pocket of the profile in motion on theconveying means, allaying the concentration of discharge on the claws(represented by the reference numeral 29 in FIG. 4, for example)protruding into the pouring pocket, and ensuring easy dischargethroughout the entire inner surface of the pouring pocket.

As the material for the electrode, aluminum, stainless steel, iron, orcopper may be used either in a form devoid of a coating or in a formlined with such a dielectric as silicone rubber as illustrated in FIG.4.

FIG. 9 illustrates the structure of an electrode which can be used mostadvantageously for the method of the present invention. This electrode20 f comprises a solid base part 26 a shaped like a round rod, a hollowpart 26 b formed in the lower terminal portion of the base part 26 a,and a multiplicity of wires 28 whose upper ends are bundled, inserted inthe hollow part 26 b, and fixed therein by caulking. Though the lowerpart of the base part 26 a is bent so as to be easily inserted into thepouring pocket of the profile in motion on the conveying means, it maybe in a straight shape. Generally, a standard electrode tends todischarge electricity through the leading end (edge part) thereof duringthe course of discharge. The present electrode, owing to theincorporation of the bundle of a multiplicity of wires 28 for the sakeof discharge, is effective in enlarging the area of discharge,preventing the concentration of discharge on the claws protruding intothe pouring pocket, enabling the discharge to occur throughout theentire inner surface (bottom surface and lateral surfaces) of thepouring pocket, and ensuring improvement of the surface modification ofthe coating film forming the inner surface of the pouring pocket. Theunit diameter of the wires 28, the quantity thereof, and the positionsof their leading terminals can be suitably adjusted in accordance withthe cross-sectional shape, size, etc. of the recess (pouring pocket)subjected to the discharge treatment. In the case of the standard heatinsulating profile, it is desirable that the unit diameter of the wiresbe not more than 1 mm, preferably in the range of 0.1-0.7 mm, and thequantity thereof be not more than 100. Optionally, the component wiremay be formed by intertwining still thinner wires. In this case, sincethe leading terminal parts of the wires come apart and expose theleading terminal parts of a greater number of thinner wires, they alloweasy discharge of electricity. Since the component wires are furtherendowed with elasticity, they are at an advantage in resuming theiroriginal shape perfectly after the discharge treatment which isperformed while they are sliding in a bent form on the inner surface ofthe pouring pocket.

FIG. 10 schematically illustrates the state in which a corona dischargetreatment is performed on the profile 1 which is in motion on aconveying device 40 of the conveyor roller type.

The electrode 20 is fitted to an elevating plate 30 through the mediumof the porcelain insulator 22 and the periphery of the electrode 20 isenclosed with an electrode cover 31 made of synthetic resin and fittedto the elevating plate 30. The reference numeral 32 represents anelectrode gap adjuster for. adjusting the distance between the leadingterminal of the electrode 20 and the profile 1. The conveying device 40is provided in the part thereof falling directly below the electrode 20with a metallic drive roller 41, which is connected to the groundingside of a high-frequency oscillator 33. The electrode 20 is connected toa high-voltage transformer 34 through the medium of the high-voltagelead wire 23. When the corona discharge is generated by the applicationof a high voltage between the electrode 20 inserted in the pouringpocket 1 a of the profile 1 and the profile 1 held in contact with themetallic drive roller 41, therefore, the corona discharge treatment iscontinuously performed on the inner surface of the pouring pocket la ofthe profile 1 which is in motion on the conveying device 40. The otherdrive rollers 42 used in the conveying device 40 are rollers lined withrubber. Though the speed of conveyance of the profile is suitablyadjusted, it is preferred to be in the approximate range of 5-60 m/min.The high-frequency power source for the corona discharge has a frequencygenerally in the range of 8,000-35,000 Hz, preferably below 10,000 Hz,and a voltage of not less than 0.5 kV, preferably not less than 3 kV.

Incidentally, the corona discharge treatment is effected at a highfrequency and a high voltage. The high-voltage part, when approached bya human body, has the possibility of emitting a spark and burning theskin of the human body. For preventing this accident, the electrode 20and the metallic drive roller 41 are encircled with a protective frame,which is omitted from illustration here by reason of a limited space.When the corona discharge is effected in the air, it emits O₃ andNO_(x), which have adverse effects on the health of the operator. Theroom in which the treatment is performed, therefore, must be furnishedwith a duct extended to the exterior of the room so that the air thereinmay remain clean at all times. Alternatively, the protective framementioned above may be substituted by a protective box which is adaptedto ventilate the room interior.

FIG. 11 schematically illustrates the structure of an electrode positionadjusting device 50. The electrode position adjusting device 50 isfurnished with a pair of laterally disposed supporting bases 51 a and 51b, a sliding table 55 slidably mounted on the supporting bases 51 a and51 b, and a framework 60 as a supporting member raised erect from therear edge part of the sliding table 55.

On the upper sides of the supporting bases 51 a and 51 b, rails 52 a and52 b are disposed perpendicularly to the conveying device mentionedabove and parallel to the metallic drive roller 41 as centeredtherearound. On one lateral part of the supporting base 51 b, a threadedrod 53 fitted with a handle 54 is rotatably disposed as shown in FIG.11. On one lateral part of the sliding table 55, a female screw member56 of ball thread adapted to mesh with the threaded rod 53 mentionedabove is fixedly secured. In the central part of the lower side of thesliding table 55, a rotary shaft 57 is rotatably disposed parallel tothe rails 52 a and 52 b. To the leading terminal of the rotary shaft 57,a handle 58 is fitted. To the rear terminal thereof, a bevel gear 59 isfitted. In the central part of the framework 60 raised upright from therear edge part of the sliding table 55, a threaded rod 61 for verticallymoving the elevating plate is disposed in a vertical direction. To thelower terminal of the threaded rod 61, a bevel gear 62 adapted to meshwith the bevel gear 59 of the rotary shaft 57 mentioned above is fitted.On the front sides of the opposite frames of the framework 60, a pair oflaterally opposite guide bars 63 a and 63 b are disposed in the verticaldirection as separated by a prescribed distance. Stoppers 64 a and 64 bare fitted to the predetermined position of the guide bars 63 a and 63b. On the rear side of the vertical part 30 a of the elevating plate 30having the electrode (the electrode 20 f illustrated in FIG. 9 in thestructure illustrated in FIG. 11) fitted thereto through the medium ofthe porcelain insulator 22, a female screw member 65 is disposed on thecenter thereof and a pair of guide members 66 a and 66 b are disposed oneither lateral sides thereof, each projected rearward. The female screwmember 65 is meshed with the threaded rod 61. The guide bars 63 a and 63b mentioned above are inserted through the vertical through holes of theguide members 66 a and 66 b.

Now, the operation of the electrode position adjusting device 50 will beexplained below. First, when the threaded rod 53 is rotated with thehandle 54, the sliding table 55 is slid forward and backward on therails 52 a and 52 b of the supporting bases 51 a and 51 b through themedium of the female screw member 56 which is meshed with the threadedrod 53. The sliding table 55 is adapted to assume its vertical positionat a predetermined distance below from the driving rollers 41 and 42 ofthe conveying device 40 illustrated in FIG. 10. After the sliding table55 has been advanced until the electrode 20 f is positioned on theprofile conveying path of the conveying device 40, the rotary shaft 57is rotated with the handle 58. As a result, the threaded rod 61 isrotated through the medium of the bevel gear 62 meshed with the bevelgear 59 at the rear terminal of the rotary shaft 57. In consequence ofthis rotation of the threaded rod 61, the elevating plate 30 is made toproduce a vertical motion through the medium of the female screw member65 which is meshed with the threaded rod 61. The fall of the elevatingplate 30 is stopped when the lower terminal of the vertical part 30 athereof collides against the stopper 64 a and 64 b and is no longerallowed to continue. Thus, the lowermost position of the electrode 20 fis fixed by the stoppers 64 a and 64 b. In order for the lowermostposition to be adjusted when the electrode is replaced, the stoppers 64a and 64 b may be fitted vertically adjustably to the guide bars 63 aand 63 b.

After the position of the electrode 20 f on the conveying device 40 hasbeen adjusted as described above, the profile 1 is conveyed on theconveying device 40 as illustrated in FIG. 10 and the pouring pocket lathereof is meanwhile subjected to the discharge treatment.

Optionally, the guide bars 63 a and 63 b formed in a prescribed lengthmay be fixed to the vertical part 30 a of the elevating plate 30 andthese guide bars may be fitted vertically movably to the framework 60and adapted such that the fall of the elevating plate 30 may stop whenthe lower terminals of the guide bars collide against the upper sides ofthe sliding table 55. For the purpose of allowing automatic adjustmentof the positions of the electrode 20 f in the forward and the backwarddirection when the profile 1 being conveyed on the conveying device 40deviates from the path of conveyance, a profile position sensor may bedisposed at a prescribed position of the conveying device 40 and an ACservo motor, for example, may rotate the threaded rod 53 in response toa signal from the sensor so as to set the electrode 20 f in the rightposition.

FIG. 12 and FIG. 13 illustrate the state in which the dischargetreatment is performed on the profile 1 in conveyance, respectively withthe electrode 20 c shaped like a plate as illustrated in FIG. 6 and theelectrode 20 d shaped like a disc as illustrated in FIG. 7 inserted intothe pouring pocket 1 a of the profile 1.

The pouring pocket 1 a of the profile 1 which has undergone thedischarge treatment as described above is then filled with resin asillustrated in FIG. 14.

FIG. 14 illustrates one example of the injection of urethane resin.Isocyanate and polyol which have been pneumatically conveyed in avolumetric ratio of 1:1 from the respective storage tanks (not shown)are fed into a mixing chamber 70 and stirred therein with a mixing rotor71. The resultant mixture is continuously injected via an injection pipe72 into the pouring pocket 1 a of the profile 1 being conveyed on theconveying device (FIG. 10). After the resin injection operation, themixing chamber 70 has the interior thereof cleaned with a solvent.Though the conditions for the injection of the resin may be suitably setdepending on such factors as the inner volume of the pouring pocket, itis generally advantageous to fix the conveying speed of the profile inthe approximate range of 10-30 m/min., the rotating speed of the mixingrotor 71 in the approximate range of 3,000-5,000 revolutions per min.,and the amount of the urethane resin to be released in the approximaterange of 1-5 liters/min. The position of the injection pipe 72 may beadjusted essentially in the same way as described above in respect tothe adjustment of the position of electrode.

After the urethane resin which has been injected is set, part of thebottom portion 1 b of the pouring pocket 1 a is cut. This practice isthe same as in the production of the conventional heat insulatingprofile, it will be omitted from the description given below.

Then, the heat insulating profile manufactured in accordance with thepresent invention will be described below with reference to specificdata.

The samples manufactured herein were extruded profiles of aluminumelectrophoretically coated with three kinds of acrylic coating material,with the pouring pockets thereof subjected to a corona dischargetreatment and then filled with urethane resin.

FIG. 15 through FIG. 17 show changes of the amount of functional groupsin the surface of a coating film before and after the dischargetreatment; FIG. 15 representing the data obtained of a matt coatingmaterial, FIG. 16 the data of a white matt coating material, and FIG. 17the data of a luster coating material. As clearly noted from theanalytical results shown in FIG. 15 through FIG. 17 that the dischargetreatment resulted in a conspicuous increase of the —COOH group. Thismarked improvement may be logically explained by a supposition that thedischarge treatment resulted in cutting the ester bonds of the acrylicresin. The changes of the amount of functional groups (vertical axis)shown in FIG. 15 through FIG. 17 were obtained by causing a reactionreagent, i.e. silver nitrate with respect to —COOH, p-chlorophenylisocyanate with respect to —OH, or p-chlorophenyl hydrazine with respectto —C═O, to react with the surface of a given coating film, thenanalyzing the reagent fixed on the surface of the coating film with ESCA(electron spectroscopy for chemical analysis) to determine theESCA-sensitive element (silver, chlorine) of the reagent, and displayingthe magnitudes of relative intensity of the peaks (ESCA output) in thecurves. While the reagent is fixed on the surface of the coating filmwhen a functional group capable of reacting with the reagent is presentin the surface of the coating film, the reagent is easily washed out(with a solvent in the absence of such a functional group.

Before and after the discharge treatment, a water drop of 5 μl waspoured on the surface of a given coating film and the surface wasexamined to determine the area (diameter) of the surface covered withthe spread film of water. The results are shown in the following table.

TABLE Spread of wet with water drops (diameter, mm) Kind of coating Nodischarge Discharge film treatment made treatment made Matt coating 2.83.7-3.8 material Luster coating 2.9 3.9 material White matt coating2.7-2.8 3.7-3.8 material

It is clearly noted from the table given above that on all the coatingfilms, the discharge treatment widened the area of spread of water,added to the wettability (hydrophilicity) of the coating film, orexalted the surface tension.

Then, from the manufactured heat insulating profiles, test pieces (50×43mm=2150 mm², urethane resin thickness about 6 mm, layer composition:electrophoretically coated aluminum sheet/urethaneresin/electrophoretically coated aluminum sheet) were cut and subjectedto a tensile test. The test was performed after the urethane resinpoured in the profile was left curing for 24 hours. In the test, thetension was applied perpendicularly to the surface of the test piece ata rate of 1 mm/min. As a result, the maximum tensile strength, 311.3 kgf(matt coating material), 363.7 kgf (luster coating material), and 449.2kgf (white matt coating material) (invariably the average value of threemeasurements), was obtained.

In a separate test for shear strength which was carried out by keepingone of the electrophoretically coated aluminum sheet fixed and applyinga load to the other electrophoretically coated aluminum sheet under thecondition of shear rate of 1 mm/min., the maximum shear strength, 305.7kgf (matt coating material), 594.5 kgf (luster coating material), and477.8 kgf (white matt coating material) (invariably the average of threemeasurements), was obtained.

It is noted from the test results mentioned above that the dischargetreatment fairly added to the adhesive strength of the profile and theresin.

Then, heat insulating profiles designed for left vertical frame, rightvertical frame, upper frame, and lower frame were manufactured in thesame manner as described above, with or without a discharge treatment.They were retained at 60° C. for 16 hours, at 23° C. for one hour, thenat −20° C. for six hours, and thereafter at 23° C. for one hour, andsubsequently they were returned to the first retention at 60° C. for 16hours. This cycle of heat treatment was repeated by way of acooling-heating repeating test. The results are shown in FIG. 18.

It is clearly noted from FIG. 18 that the discharge treatment preventedthe packed urethane resin from shrinking after the cooling-heatingrepeating test mentioned above. The profiles for the left verticalframe, right vertical frame, upper frame, and lower frame which hadundergone the discharge treatment registered identical results. FIG. 18,therefore, shows one representative data.

While certain specific embodiments have been disclosed herein, theinvention may be embodied in other specific forms without departing fromthe spirit or essential characteristics thereof. The describedembodiments are therefore to be considered in all respects asillustrative and not restrictive, the scope of the invention beingindicated by the appended claims rather than by the foregoingdescription and all changes which come within the meaning and range ofequivalency of the claims are, therefore, intended to be embracedtherein.

What is claimed is:
 1. A resin-composite heat insulating aluminumprofile, comprising: an aluminum profile comprising a pair of lateralsheet members having a coating film applied thereon, said coating filmbeing formed from a coating material capable of forming a functionalgroup, which reacts with isocyanate, in consequence of a dischargetreatment, at least part of the coated surface of said profile beingdischarge treated and including at least a pair of discharge treated,opposed recesses respectively formed in opposed surfaces of said lateralsheet members, and a joining member of a urethane resin joined to thedischarge treated recesses of said aluminum profile, said urethane resinbeing substantially formed of isocyanate and polyol.